{"id":6359,"date":"2025-04-03T13:40:19","date_gmt":"2025-04-03T13:40:19","guid":{"rendered":"http:\/\/flovel.net.localhost\/nilwande\/"},"modified":"2025-04-03T13:40:19","modified_gmt":"2025-04-03T13:40:19","slug":"nilwande","status":"publish","type":"post","link":"https:\/\/flovel.net\/es\/nilwande\/","title":{"rendered":"Nilwande"},"content":{"rendered":"<div id=\"ep-breadcrumbs-block_67a442f78a997349ed23c65eacf112cb\" class=\"ep-breadcrumbs ep-block \">\n            <div class=\"show-frontend\">\n            <div class=\"inner\">\n                                    <p id=\"breadcrumbs\"><span><span><a href=\"https:\/\/flovel.net\/es\/\">Home<\/a><\/span><\/span><\/p>\n                            <\/div>\n        <\/div>\n    <\/div>\n\n\n<div id=\"ep-disturber-block_3217f20b09ba265289b013d8f75ed1a7\" class=\"ep-disturber ep-block \">\n            <div class=\"show-frontend\">\n            <div class=\"inner\">\n                                                                            \n                                                                                <picture>\n                        <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/disturber1290x620-technology-nilwande01-1290x620-c-center.jpg 1x\" media=\"(min-width: 1024px)\"\/>\n                        <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/disturber1290x620-technology-nilwande01-1024x0-c-center.jpg 1x\" media=\"(min-width: 768px)\"\/>\n                        <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/disturber1290x620-technology-nilwande01-768x0-c-center.jpg 1x\" media=\"(max-width: 767px)\"\/>\n                        <img decoding=\"async\" src=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/disturber1290x620-technology-nilwande01-768x0-c-center.jpg\" alt=\"\" title=\"Disturber1290x620_Technology_Nilwande01\"\/>\n                    <\/picture>\n                                            <\/div>\n        <\/div>\n    <\/div>\n\n<div id=\"ep-block-spacer-block_b258c68cf410d7181a0faa004fc4231b\" class=\"ep-block-spacer ep-block \">\n            <section  class=\"show-frontend  \">\n                        <style>\n                #ep-spacer-uQxTJ {\n                    height: 80px;\n                }\n\n                @media (max-width: 767px) {\n                    #ep-spacer-uQxTJ {\n                        height: 40px;\n                    }\n                }\n\n                @media (min-width: 768px) and (max-width: 1023px) {\n                    #ep-spacer-uQxTJ {\n                        height: 60px;\n                    }\n                }\n            <\/style>\n            <div id=\"ep-spacer-uQxTJ\"><\/div>\n        <\/section>\n    <\/div>\n\n<div id=\"ep-title-text-block_89cb62e63eb39c93e7d97472a0cf35fa\" class=\"ep-title-text ep-block \">\n            <div class=\"show-frontend\">\n            <div class=\"inner alignment-center\">\n                                    <h2 class=\"title \">Nilwande Project<\/h2>\n                                                    <div class=\"text\">\n                        <p>Wide head range and high head Kaplan<\/p>\n\n                    <\/div>\n                            <\/div>\n        <\/div>\n    <\/div>\n\n\n<div id=\"ep-block-spacer-block_547e5aede3a3ba844bef32ae2c5043bb\" class=\"ep-block-spacer ep-block \">\n            <section  class=\"show-frontend  \">\n                        <style>\n                #ep-spacer-l9WDy {\n                    height: 30px;\n                }\n\n                @media (max-width: 767px) {\n                    #ep-spacer-l9WDy {\n                        height: 20px;\n                    }\n                }\n\n                @media (min-width: 768px) and (max-width: 1023px) {\n                    #ep-spacer-l9WDy {\n                        height: 20px;\n                    }\n                }\n            <\/style>\n            <div id=\"ep-spacer-l9WDy\"><\/div>\n        <\/section>\n    <\/div>\n\n\n<div class=\"wp-block-group\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\"><div id=\"ep-wysiwyg-block_0f2325e784aba0ebcd1a797778ef4e8d\" class=\"ep-wysiwyg ep-block \">\n                        <section class=\"show-frontend\">\n                <div class=\"inner\">\n                    <p><strong>Introduction<\/strong><br \/>\nFLOVEL successfully accomplished the challenging design of Kaplan turbine for the NILWANDE Project.<\/p>\n<p><strong>Parameters<\/strong><br \/>\nThe NILWANDE HPP is equipped with two (2) units of Kaplan machines running at synchronous speed of 428.6 rpm, operating under rated net head of 38.5 m. Each unit can generate output of 3,500 kW + 20% continuous overload. The powerhouse is situated at an elevation of 593.50 m above mean sea level with maximum temperature of (+) 400C. The scheme of the project and is a run-off the river type.<\/p>\n<p><strong>Plant parameters:<\/strong><\/p>\n<ul>\n<li>Number of Units: 02<\/li>\n<li>Type of turbine: Vertical Kaplan<\/li>\n<li>Maximum Head: 58.5 m<\/li>\n<li>Maximum Design pressure: 7.5 bar<\/li>\n<li>Rated turbine output: 3,780 kW + 20% COL<\/li>\n<li>Synchronous speed: 428.6 rpm<\/li>\n<li>Runaway speed: 1,065 rpm<\/li>\n<li>Speed rise: 50%<\/li>\n<li>Pressure rise: 25%<\/li>\n<\/ul>\n<p><strong>Turbine type definition<\/strong><br \/>\nThe consideration for turbine selection is mostly concentrated in the following aspects:<br \/>\nEnvironmental \u2013 Economic \u2013 Technical \u2013 Operational<\/p>\n<p>Since the heads in this project are in the higher side when considering the Kaplan application range, the possibility of Francis machines could not be discarded in a first approach. However, in the comparison with Francis machines the Kaplan alternative has the following positive aspects to be considered:<\/p>\n<ul>\n<li>Smooth operation to low flow<\/li>\n<li>Higher efficiency over a wide range<\/li>\n<li>Higher specific speed and rotational speed<\/li>\n<\/ul>\n<p>In the other side we have the Francis alternative well known as less expensive machine solution.<\/p>\n<p>In NILWANDE Project the Customer definition was that only Kaplan with vertical shaft system would be acceptable since the viability of project was based on annual energy generation and hence the entire range to be explored.<\/p>\n<p>The final selection to meet the requirements of operating flexibility in a wide range of heads (18.5 to 58.5 m) as well as high maximum head for a Kaplan turbine presents the following main characteristics:<\/p>\n<ul>\n<li>Vertical turbine with metallic spiral casing.<\/li>\n<li>Direct driven generator.<\/li>\n<li>Runner diameter of 1,600 mm.<\/li>\n<li>Runner with 8 no. blades.<\/li>\n<li>Double regulated turbine.<\/li>\n<\/ul>\n<p>The rotation speed was also unique selection for a Kaplan turbine and 428.6 rpm was the selected.<\/p>\n<p><strong>Design challenges<\/strong><br \/>\nTo design a runner with 1,600 mm diameter in which a set of 8 blades are required was the most demanding. In fact, the design should accommodate inside of a relatively small runner hub, the set of blades trunnions, blades mechanism i.e., links and levers as well as the runner servomotor. More difficult the task is when the maximum head is of 58.5 m, being close to Kaplan limit of around 70 m.<\/p>\n<p>Based on all the above design requirement and constraints it was expectable that we would find forces, pressures, stresses and strains close to admissible limits. During first steps of design and calculation it was confirmed and one of the measures taken, as an example, was the material of runner hub. Conventional material used in regular applications was not strong enough to withstand the loads. Special steel material was applied.<\/p>\n<p>The use of 3D technology in this complex type of design is crucial in avoiding mismatches and mistakes that can require major rework at shop assembly, which also can lead to a loss of strength of parts. Each volume of part was defined within the limits, not allowing further reduction due to not expected interference.<\/p>\n\n                <\/div>\n            <\/section>\n            <\/div>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\"><div id=\"ep-gallery-block_a6160c4cabf3b460328f30d3e98399c1\" class=\"ep-gallery ep-block \">\n                        <div class=\"show-frontend\">\n                <div class=\"inner\">\n                    <div class=\"items cols-1\">\n                                                    <div class=\"item\">\n                                                                                                \n                                                                                                                                                                <picture>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande03-600x400-c-center.jpg 1x\" media=\"(min-width: 1024px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande03-600x400-c-center.jpg 1x\" media=\"(min-width: 768px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande03-600x400-c-center.jpg 1x\" media=\"(max-width: 767px)\"\/>\n                                    <img decoding=\"async\" src=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande03-600x400-c-center.jpg\" alt=\"\" title=\"Gallery1280x853_Technology_Nilwande03\"\/>\n                                <\/picture>\n                                <a href=\"#gallery-item-modal-Eu2ob\" data-image=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande03-1024x0-c-default.jpg\" class=\"btn gallery-item open-modal\">\n                                    <span><i class=\"fa-light fa-plus-circle\"><\/i><\/span>\n                                <\/a>\n                            <\/div>\n                                                    <div class=\"item\">\n                                                                                                \n                                                                                                                                                                <picture>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande04-600x400-c-center.jpg 1x\" media=\"(min-width: 1024px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande04-600x400-c-center.jpg 1x\" media=\"(min-width: 768px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande04-600x400-c-center.jpg 1x\" media=\"(max-width: 767px)\"\/>\n                                    <img decoding=\"async\" src=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande04-600x400-c-center.jpg\" alt=\"\" title=\"Gallery1280x853_Technology_Nilwande04\"\/>\n                                <\/picture>\n                                <a href=\"#gallery-item-modal-Eu2ob\" data-image=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande04-1024x0-c-default.jpg\" class=\"btn gallery-item open-modal\">\n                                    <span><i class=\"fa-light fa-plus-circle\"><\/i><\/span>\n                                <\/a>\n                            <\/div>\n                                                    <div class=\"item\">\n                                                                                                \n                                                                                                                                                                <picture>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande01-600x400-c-center.jpg 1x\" media=\"(min-width: 1024px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande01-600x400-c-center.jpg 1x\" media=\"(min-width: 768px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande01-600x400-c-center.jpg 1x\" media=\"(max-width: 767px)\"\/>\n                                    <img decoding=\"async\" src=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande01-600x400-c-center.jpg\" alt=\"\" title=\"Gallery1280x853_Technology_Nilwande01\"\/>\n                                <\/picture>\n                                <a href=\"#gallery-item-modal-Eu2ob\" data-image=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande01-1024x0-c-default.jpg\" class=\"btn gallery-item open-modal\">\n                                    <span><i class=\"fa-light fa-plus-circle\"><\/i><\/span>\n                                <\/a>\n                            <\/div>\n                                                    <div class=\"item\">\n                                                                                                \n                                                                                                                                                                <picture>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande02-600x400-c-center.jpg 1x\" media=\"(min-width: 1024px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande02-600x400-c-center.jpg 1x\" media=\"(min-width: 768px)\"\/>\n                                    <source srcset=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande02-600x400-c-center.jpg 1x\" media=\"(max-width: 767px)\"\/>\n                                    <img decoding=\"async\" src=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande02-600x400-c-center.jpg\" alt=\"\" title=\"Gallery1280x853_Technology_Nilwande02\"\/>\n                                <\/picture>\n                                <a href=\"#gallery-item-modal-Eu2ob\" data-image=\"https:\/\/flovel.net\/wp-content\/uploads\/2025\/04\/gallery1280x853-technology-nilwande02-1024x0-c-default.jpg\" class=\"btn gallery-item open-modal\">\n                                    <span><i class=\"fa-light fa-plus-circle\"><\/i><\/span>\n                                <\/a>\n                            <\/div>\n                                            <\/div>\n                <\/div>\n            <\/div>\n            <\/div>\n    <div class=\"modal \" id=\"gallery-item-modal-Eu2ob\">\n        <div class=\"modal-inner\">\n            <a href=\"#\" class=\"close-modal btn\">\n                <i class=\"fa-light fa-circle-minus\"><\/i>\n            <\/a>\n            <div class=\"body\">\n                            <\/div>\n        <\/div>\n    <\/div>\n<\/div>\n<\/div>\n<\/div><\/div>\n\n\n\n<div class=\"wp-block-group\"><div class=\"wp-block-group__inner-container is-layout-constrained wp-block-group-is-layout-constrained\">\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-9d6595d7 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\"><div id=\"ep-wysiwyg-block_86e30d5f8ff6342137719deb002308da\" class=\"ep-wysiwyg ep-block \">\n                        <section class=\"show-frontend\">\n                <div class=\"inner\">\n                    <p>Due to space restriction inside runner hub the servomotor sizing required special care as well. Reduced space implies in transmission torque arms also reduced. High pressure oil system was select. The servomotor capacity was determined based on a design torque that is know from experience to be higher than the real one. An appropriate margin to account for friction in the mechanism was considered with standard design of self-lubricating bushings for lower friction operation. Under this overview the runner servomotor capacity was defined.<\/p>\n<p>Due to space restriction inside runner hub the servomotor sizing required special care as well. Reduced space implies in transmission torque arms also reduced. High pressure oil system was select. The servomotor capacity was determined based on a design torque that is know from experience to be higher than the real one. An appropriate margin to account for friction in the mechanism was considered with standard design of self-lubricating bushings for lower friction operation. Under this overview the runner servomotor capacity was defined.<\/p>\n\n                <\/div>\n            <\/section>\n            <\/div>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\"><div id=\"ep-wysiwyg-block_7fcd3a4ea4483cbca2f98980d71092db\" class=\"ep-wysiwyg ep-block \">\n                        <section class=\"show-frontend\">\n                <div class=\"inner\">\n                    <p><strong>Observations and Conclusions<\/strong><br \/>\nAfter the commissioning of machines in the NILWANDE HPP, the design validation was done based on the observation that:<\/p>\n<ul>\n<li>The selected Kaplan type is proven to be the right choice of machine from the operational point of view and it is understood that viability based on annual energy generation was achieved by Customer.<\/li>\n<li>Selection of correct number of blades was also confirmed as most suitable since performance and operation in a wide range was verified.<\/li>\n<li>Rotation speed as well was confirmed to be most economical solution considering generator selection.<\/li>\n<li>The proper design of the complex mechanism and perfect assembly have been previously checked during factory testing.<\/li>\n<li>Runner servomotor capacity was attested during commissioning tests.<\/li>\n<li>All the environmentally friendly features applied in this project are helping in its sustainability.<\/li>\n<\/ul>\n\n                <\/div>\n            <\/section>\n            <\/div>\n<\/div>\n<\/div>\n<\/div><\/div>\n\n\n<div id=\"ep-block-spacer-block_ccd3234e2647af033049877533eaff03\" class=\"ep-block-spacer ep-block \">\n            <section  class=\"show-frontend  \">\n                        <style>\n                #ep-spacer-nRfDj {\n                    height: 100px;\n                }\n\n                @media (max-width: 767px) {\n                    #ep-spacer-nRfDj {\n                        height: 50px;\n                    }\n                }\n\n                @media (min-width: 768px) and (max-width: 1023px) {\n                    #ep-spacer-nRfDj {\n                        height: 80px;\n                    }\n                }\n            <\/style>\n            <div id=\"ep-spacer-nRfDj\"><\/div>\n        <\/section>\n    <\/div>\n\n<div id=\"ep-title-text-block_e0b5f2e948a579053e62bfe3c26d39f7\" class=\"ep-title-text ep-block \">\n            <div class=\"show-frontend\">\n            <div class=\"inner alignment-left\">\n                                    <h4 class=\"title \">About FLOVEL:<\/h4>\n                                            <\/div>\n        <\/div>\n    <\/div>\n\n\n<div id=\"ep-block-spacer-block_fc25f486f18342d626190ff974ee34f7\" class=\"ep-block-spacer ep-block \">\n            <section  class=\"show-frontend  \">\n                        <style>\n                #ep-spacer-IMHar {\n                    height: 20px;\n                }\n\n                @media (max-width: 767px) {\n                    #ep-spacer-IMHar {\n                        height: 20px;\n                    }\n                }\n\n                @media (min-width: 768px) and (max-width: 1023px) {\n                    #ep-spacer-IMHar {\n                        height: 20px;\n                    }\n                }\n            <\/style>\n            <div id=\"ep-spacer-IMHar\"><\/div>\n        <\/section>\n    <\/div>\n\n<div id=\"ep-wysiwyg-block_55af41fdaf0bbfb99e9e023c508d62c7\" class=\"ep-wysiwyg ep-block \">\n                        <section class=\"show-frontend\">\n                <div class=\"inner\">\n                    <p>FLOVEL name has been synonymous with the hydro power sector for over four decades. FLOVEL is a full-line supplier of electromechanical equipment and services for small and medium size hydro power plants manufacturer of hydraulic turbines, valves and turnkey supplier of electro mechanical packages for hydro power projects and ranks amongst the leading players globally. FLOVEL manufacturers complete range of Pelton, Francis, Kaplan, Axial Flow turbines and Valves for hydropower projects. The strength of FLOVEL is in its ability to offer all-inclusive solutions (Electro Mechanical-Turnkey Packages).<\/p>\n\n                <\/div>\n            <\/section>\n            <\/div>\n\n\n<div id=\"ep-block-spacer-block_ccd3234e2647af033049877533eaff03\" class=\"ep-block-spacer ep-block \">\n            <section  class=\"show-frontend  \">\n                        <style>\n                #ep-spacer-tNKnW {\n                    height: 100px;\n                }\n\n                @media (max-width: 767px) {\n                    #ep-spacer-tNKnW {\n                        height: 50px;\n                    }\n                }\n\n                @media (min-width: 768px) and (max-width: 1023px) {\n                    #ep-spacer-tNKnW {\n                        height: 80px;\n                    }\n                }\n            <\/style>\n            <div id=\"ep-spacer-tNKnW\"><\/div>\n        <\/section>\n    <\/div>\n\n<div id=\"ep-forms-block_9b2d3f3b44f6a7336c7b54aeef269c28\" class=\"ep-forms ep-block \">\n            <div class=\"show-frontend\">\n            <div class=\"inner\">\n                <div class=\"holder\">\n                                            <h2>Get in touch with FLOVEL<br \/>\r\n<\/h2>\n                    \n                                            <div class=\"text\"><p>FLOVEL believes in customer delight. With its technological expertise and senior management&#8217;s commitment it brings the Small &amp; Medium Hydro projects alive on time, with maximum performance and minimum downtime. Years of experience have also enabled us to think through and implement projects calmly and clearly. Our customers are glad to have chosen FLOVEL for their Hydropower project.<\/p>\n<\/div>\n                    \n                                            <style id=\"wpforms-css-vars-202\">\n\t\t\t\t#wpforms-202 {\n\t\t\t\t--wpforms-field-size-input-height: 43px;\n--wpforms-field-size-input-spacing: 15px;\n--wpforms-field-size-font-size: 16px;\n--wpforms-field-size-line-height: 19px;\n--wpforms-field-size-padding-h: 14px;\n--wpforms-field-size-checkbox-size: 16px;\n--wpforms-field-size-sublabel-spacing: 5px;\n--wpforms-field-size-icon-size: 1;\n--wpforms-label-size-font-size: 16px;\n--wpforms-label-size-line-height: 19px;\n--wpforms-label-size-sublabel-font-size: 14px;\n--wpforms-label-size-sublabel-line-height: 17px;\n--wpforms-button-size-font-size: 17px;\n--wpforms-button-size-height: 41px;\n--wpforms-button-size-padding-h: 15px;\n--wpforms-button-size-margin-top: 10px;\n--wpforms-container-shadow-size-box-shadow: none;\n\t\t\t}\n\t\t\t<\/style><div class=\"wpforms-container 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